Stackable modular container system

ABSTRACT

The present invention relates to a stackable-modular container system comprising stackable modules, each module comprising a top and bottom modular shelf defining compartment or base plate for receiving a modular container, each of the top and bottom base plate having four corners comprising a hole at each corner, wherein the holes are sized and configured for interferingly receiving one end of a modular frame member, each frame member comprising a top end and a bottom end, the ends sized and configured for mating engagement with the holes on the top and bottom modular base plates respectively, the frame member having a notch proximal to the top end for slidable engagement with integral peripheral flange on the container.

FIELD OF THE INVENTION

This invention relates to a stackable modular container system for use in homes, offices or workshops for work space organization. More specifically, the present invention relates to a container and shelving system for storing items in a stackable assembly having a plurality of containers into which items requiring processing such as laundering can be separated according to the type of processing step desired.

BACKGROUND OF THE INVENTION

When a plurality of containers are used to hold items to be segregated by size, type, color, weight or the like, such as laundry, trash or the like, it is often a convenient savings of floor space if such containers can be stacked on each other. However, for storage, shipment, marketing/display and like purposes, it is desirable that these same containers have the ability to nest within each other in a space conservation effort.

Many varieties of such nestable, yet stackable, containers are known in the art. Most, however, suffer from one or more deficiencies. For example, in many such containers, the stable stacking thereof is not a simple process with the user having to exercise a high degree of care in tending to the proper stacking placement of the containers. In addition, when stacked, most prior art arrangements do not provide a conveniently sufficient access opening, and in some instances, the containers actually must be at least partially unstacked in order to gain access to the contents.

U.S. Pat. No. 4,057,309 to Fragale discloses a clothes hamper having a central horizontal partition-shelf defining an upper, open-topped compartment and a lower, open-fronted compartment, a plurality of upper, open topped, free-standing sub-containers removably mounted on the partition shelf, and a plurality of lower, open-topped, free-standing sub-containers mounted below the hamper below the partition for movement into and out of the hamper through a front wall opening.

U.S. Pat. No. 6,062,416 to Smillie discloses a hamper comprising two lower compartments for storing bulkier items and two inner compartments arranged to pivot within the container from a position wherein the inner compartment(s) are within the container to an outward position wherein the inner compartments are outward of the container. The inner compartments are arranged to accept one or more rigid inserts.

U.S. Pat. No. 7,000,798 to Robert et al. discloses a laundry hamper for individually storing laundry into 4 or 8 chambers into which garments and items requiring laundering can be separated according to wash cycle required. The laundry hamper consists of a box-like structure having four side doors with fasteners on each door and the underside of the structure to hold a laundry bag open. The entire structure is mounted on a turntable to be rotated to select the appropriate laundry bag for the item to be washed.

By “modular”, it is meant that the container contains easily disassemblable and assemblable modules. This ability gives the container the important feature of being shipped in pieces which greatly reduces freight costs for unassembled containers.

To be useful, modular container systems should meet and exceed Rack Manufacturers Institute standards for dynamic loading. Basically this means that when assembled, the modular containers should not be too shaky and should be able to support loading adequate for its intended uses.

SUMMARY OF THE INVENTION

It is one object of the present invention to provide a modular stackable container system which meets the Rack Manufacturers Institute standards wherein the modular connection joints adequately resist bending forces.

It is another object to provide a sorting unit that is children-friendly. It is difficult, if not impossible for small children to manipulate laundry holding units as they fill up with laundry and get heavy and bulky.

A still further object is to provide a plurality of labelable containers and/or shelving, each shelving containing a removable storage unit.

It is a further object to provide shelving when the containers are removed from the arrangement.

It is an objective to provide a truly expandable (increasable or decreasable) unit. As family sizes/sort categories increase more units can be added (unlimited), as family sizes/sort categories decrease, units can be removed and sold or stored for later use. If a unit gets damaged, only the part needed will be replaced. This modular container system can be used for a life time.

Another object of the invention is to provide a stackable modular container and shelving system for use in homes, offices or workshops for work space organization.

This and other objectives are attained by providing a stackable modular container and shelving system wherein a module comprises a container slidably connected with to a modular shelving framework wherein the containers slide in and out of the framework. The container system of this invention frees up space that is used to store laundry, can be used by people of all ages and can be stacked to any desired height. Neatly organized laundry is stored vertically in labeled removable storage units or containers that can be used as laundry baskets. As each storage a unit is filled, the clothing in that unit is laundered and the unit is replaced. Because the laundry is sorted as it is being used, time wasted sorting laundry is eliminated. Also because laundry is not stored in the traditional horizontal method, space used to store loads of laundry is reduced to the space it takes to store a single laundry basket.

One general embodiment of the stackable modular container system comprises stackable modules, each module comprising a top and bottom modular shelf defining compartment or base plate for receiving a modular container, each of said top and bottom base plate having four corners comprising a hole at each corner, said holes sized and configured for interferingly receiving one end of a modular frame member, each frame member comprising a top end and a bottom end, said ends sized and configured for mating engagement with the holes on the top and bottom modular base plates respectively, said frame member having a notch proximal to the top end for slidable engagement with integral peripheral flange on the container and wherein the container can slide in and out of the module.

One of ordinary skill in the art understands that the utility of the container system of the instant invention is by no means limited to laundry; the container system of the present invention being useful in any environment where better organization of items is desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side and front end perspective view of a nestable modular container according to one embodiment of this invention.

FIG. 2 is a three-dimensional view of a three-container stack using the nestable modular container of FIG. 1.

FIG. 3 is a close-up three-dimensional view of a the three-container stack of FIG. 2.

FIG. 4 is a three dimensional view of a module of the stackable modular container system according to one embodiment of the present invention.

FIG. 5 is a side and front perspective view of a base plate.

FIG. 6 is a bottom and side perspective view of a base plate.

FIG. 7 is another bottom perspective view of a base plate.

FIG. 8 is a three-dimensional view of a modular frame member.

FIG. 9 is a detailed side-perspective view of a modular frame member.

FIG. 10 is another side-perspective view of a modular frame member.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 illustrates a side and front end perspective view of a nestable modular container 10 according to one embodiment of this invention. A nestable container 10 of the present invention has two opposed side walls 12, two opposed end walls 14 between the side walls, extending taperedly and upwardly from the bottom surface 16 to an upper rim defining an open top. The container further includes an integral peripheral flange 18 at its upper edge, said flange preferably peripherally grooved 20 at its junction with the side walls 12 to provide a handling means for carrying the container. Preferably, the container also has a label receiving portion 22. Optionally the side 12 and end 14 walls of the container 10 contains decorative apertures 24.

It should be understood that the present invention has applicability to any type of container wherein it may be desirable to shelf stack like containers during use, and in particular where it is desirable to segregate items, such as laundry, in separate containers. Other typical usages would relate to the segregation of small parts or the segregation of refuse, trash, or the like for recycle purposes. In these instances, side walls 12 and end walls 14 may well be provided in a solid, as opposed to apertured, form not only for strength purposes which might be required to hold the heavier refuse, but also for confinement purposes which may be necessary considering the nature of refuse or the small parts and other miscellaneous items.

The container 10 is preferably unitarily formed from a piece of sheet material. Optionally the container 10 also includes a lid (not shown) and optional lid closure means (not shown), said lid located adjacent to the flange 18 for sealing the container to form a fully-enclosed container.

The container 10 is also capable of being nested within like containers. To that end, the side walls taper away from each other as they extend upwardly from the bottom surface with a taper of preferably three to four degrees.

Various compositions suitable for constructing the storage containers of the present invention include substantially impermeable materials such as polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyethylene (PE), polypropylene (PP), aluminum foil, coated (waxed, etc.) and uncoated paper, coated nonwovens etc., and substantially permeable materials such as scrims, meshes, wovens, nonwovens, or perforated or porous films, whether predominantly two-dimensional in nature or formed into three-dimensional structures. Such materials may comprise a single composition or layer or may be a composite structure of multiple materials, including a substrate material utilized as a carrier for a substance.

Once the desired sheet materials are manufactured in any desirable and suitable manner, comprising all or part of the materials to be utilized for the container body, the container may be constructed in any known and suitable fashion such as those known in the art. The container bodies may be thermoformed, blown, or otherwise molded.

The lid, when provided, may be constructed in any known fashion utilizing any closure configuration, such as folds, pleats, adhesives, or mechanical interlocking closures such as ribs, beads, and grooves, which are known in the art.

FIGS. 5-7 is an illustration of a base plate according to one embodiment of the present invention. The base plate is the shelving defining compartment and comprises connecting holes 62 located at its corners which allow the frame members 40 to be removably attached to the base plates. As shown in FIG. 5, a preferred base plate comprises an integral, peripheral hole bearing collar 64 optionally connected to an integral container receiving portion 66 sized and configured to receive the bottom panel 16 of the container 10. In a preferred embodiment, the container receiving portion 66 is slightly recessed from the top end of the hole bearing collar 64. As shown in FIG. 6, connecting holes 62 are integrally disposed adjacent the corners of the hole bearing collar 64.

The frame elements of the modular stackable container system of the present invention comprise modular frame members 40 joined to top and bottom modular base plates 60, said base plates bring the shelving defining compartments. See FIGS. 2-10.

FIG. 8 is a three-dimensional view of a modular frame member. FIG. 9 is a detailed side-perspective view of a modular frame member. FIG. 10 is another side-perspective view of a modular frame member. Each frame member 40 comprises a mid section 42, a top connecting end 44 and a bottom connecting end 46, each connecting end sized and configured for mating engagement with corresponding holes 62 on the base plates 60.

In a preferred embodiments the connecting ends are at least two inches long and the connecting holes 62 are at least four inches long.

In one embodiment, the frame member has a rectangular cross section. In a preferred embodiment, the rectangular cross sections are rounded out at the corners to remove any sharp edges. In another embodiment, the frame members have a circular or semi-circular cross section. In yet another embodiment, the frame members have a square cross section. In yet another embodiment, the frame members are solid. In a preferred embodiment, the frame members have a hollow interior.

The top 44 and bottom 46 connecting ends of a frame member 40 are dimensionally identical and comprise integrally formed projections extending from the collars 48 and 50 of the top and bottom connecting ends. The length of the connecting ends depend on the desired load bearing capacity of the container system and must be designed to the Rack Manufacturers Institute (RMI) standards (RMI Paragraph 8.2.2 “Stacked Load Capacity Test”) and should withstand the use in industry.

There are two types of stresses which affect the columnar frame members, axial and bending. The axial stresses are developed from loaded containers being stacked directly above one another, however, these stresses are minor. The majority of the stress is caused by bending moments on the columns. The columns must withstand both manufacturing misalignments and, more severely, a required RMI 3% grade design specification. Visually, this means that a lower most loaded modular container must be able to withstand being placed at a 3% grade with 3 or 4 fully loaded modular containers placed on top of the first container. The standard is important because it insures integrity of the stackable modules by assuring that the lower most module will not collapse due to the demanding stresses developed from any movement of loads which are supported by and above the lower most unit.

Means known in the art may be employed to provide bending stability to the stackable modules of the present invention. In a preferred embodiment, an interference fit is provided between the connecting ends 44 and 46 and the corresponding holes 62 on the base plates 60. The holes 62 are sized and configured to receive the entire length of the connecting ends 44 or 46. When the top end 44 of the frame member 40 is connected to the underside of the hole 62 on the base plate 60, the base plate rests on the collar 48. When the bottom end 46 of the frame member 40 is connected to the topside of the hole 62 on the base plate 60, the collar 50 rests on the base plate 60.

In another preferred embodiment, the holes 62 may be provided with a metallic, composite or plastic sleeve (not shown), for interferingly mating engagement with the end portions 44 and 46. As used herein, interferingly mating engagement means the closest possible fit or force fitting that may require a mechanical means to effect the mating engagement.

In yet another embodiment, the connecting ends 44 and 46 are inwardly tapered to mate with a corresponding outwardly tapered section of the holes 62 which may or may not be sleeved for interferingly mating engagement with the end portions 44 and 46.

In yet another embodiment, the base plate 60 is provided with outwardly projecting connecting holes (not shown) or hole extenders for mating with corresponding extended end portions 44 and 46 of the frame member 40 to increase the rigidity of the stackable system against bending moments. So designed, the connection holes 62 extend over a majority of the length of the frame member 42, thereby providing strength and rigidity against both axial and bending stresses. The hole extenders may on some high capacity load bearing applications be necessary to transfer dynamic stresses throughout the frame member as opposed to allowing the stresses to concentrate in a limited area where the frame member is connected to the base plates itself.

In a preferred embodiments the extended connecting ends are at least three inches long and the extended connecting holes 62 are at least six inches long.

In yet another embodiment, the hole extenders are provided with a metallic, composite or plastic sleeve for interferingly mating engagement with end portions 44 and 46.

In one embodiment, the frame-members and base plates are made of metal. In another embodiment, the frame-members and base plates are made of wood. In a preferred embodiment, the frame members and base plates are made of plastic.

FIG. 2-3 is a three-dimensional view of a three-container stack using the nestable modular container of FIG. 1. FIG. 4 is a three dimensional view of a module of the stackable modular container system according to one embodiment of the present invention. As shown in FIG. 8, proximal to the top end of the midsection 42 of the frame member 40 is a notch 52 designed to engage the integral flange 18 of the container 10 such that when assembled, the container 10 slides in and out of the frame and may when fully engaged in the four notches of the module rest on the container receiving portion 66 of the base plate 60. The size of the notch 52 depends on the size of the flange 18 and the depth of the optional recess of the container bearing portion 66 of the base plate 60. When used for laundry, a preferred container is lifted up and slid out of the assembly.

Optionally, the modular system may contain a floor base plate, alike in structure to other base plates but for a set of wheels for supporting the entire modular container system above the floor. Optionally, a separate wheel base equipped with casters may be used o contain the stackable modular container system above the floor. Optionally, end hole caps are also provided to cover the holes at the top plate to prevent objects from falling into the hole.

Thus, while specific embodiments of the present invention have been described above in detail, it will be understood by one of ordinary skill in the art that this description is to be considered in all senses illustrative rather than restrictive. Those skilled in the art will recognize other embodiments and modifications of the present invention, the scope of which is delimited solely by the following claims. 

1. A stackable modular container system comprising stackable modules, each module comprising a top and bottom modular base plate for receiving a modular container, each of said top and bottom base plate having four corners comprising a connecting hole at each corner, said connnecting holes sized and configured for receiving one end of a modular frame member, each frame member comprising a top connecting end and a bottom connecting end, said ends sized and configured for detachable mating engagement with the holes on the top and bottom modular base plates respectively, said frame member having a notch proximal to the top connecting end for slidable engagement with corresponding flange on the container and wherein the container can slide in and out of the module.
 2. The stackable modular container system of claim 1, wherein the containers are sized and configured for nesting in each other when not connected to the module.
 3. The stackable modular container system of claim 1, wherein the assembled stack is capable of withstanding a 3% grade when fully loaded with similar fully loaded stackable modules above it.
 4. The stackable modular container system of claim 1, wherein the top and bottom connecting ends of a frame member are inwardly tapered to mate with a correspondingly outwardly tapered connecting hole.
 5. The stackable modular container system of claim 1, wherein the top and bottom connecting holes are sleeved for force-fitting engagement with the connecting ends. 